WO2025040587A1 - Pale d'éolienne dotée d'un composant aérodynamique - Google Patents
Pale d'éolienne dotée d'un composant aérodynamique Download PDFInfo
- Publication number
- WO2025040587A1 WO2025040587A1 PCT/EP2024/073105 EP2024073105W WO2025040587A1 WO 2025040587 A1 WO2025040587 A1 WO 2025040587A1 EP 2024073105 W EP2024073105 W EP 2024073105W WO 2025040587 A1 WO2025040587 A1 WO 2025040587A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- aerodynamic component
- wind turbine
- turbine blade
- edge
- adhesive
- Prior art date
Links
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
- F03D1/0675—Rotors characterised by their construction elements of the blades
- F03D1/0688—Rotors characterised by their construction elements of the blades of the leading edge region, e.g. reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
- B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
- B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
- B29C65/542—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts by injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/76—Making non-permanent or releasable joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
- B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
- B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
- B29C66/61—Joining from or joining on the inside
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
- B29L2031/085—Wind turbine blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
- F05B2230/60—Assembly methods
- F05B2230/604—Assembly methods using positioning or alignment devices for aligning or centering, e.g. pins
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2240/00—Components
- F05B2240/20—Rotors
- F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
- F05B2240/303—Details of the leading edge
Definitions
- the present disclosure relates to a prefabricated aerodynamic component for a wind turbine blade and a method of attaching such a component to a body of a wind turbine blade.
- Wind is an increasingly popular clean source of renewable energy with no air or water pollution.
- wind turbine blades spin clockwise, capturing energy through a main shaft connected to a gearbox and a generator for producing electricity. Blades of modern wind turbines are carefully designed to maximise efficiency. Modern wind turbine blades may exceed 100 metres in length and 4 metres in width.
- Wind turbine blades are typically made from a fibre-reinforced polymer material, comprising a body with a pressure side shell half and a suction side shell half, also called blade halves.
- the cross- sectional profile of a typical wind turbine blade includes an airfoil for creating an air flow leading to a pressure difference between both sides. The resulting lift force generates torque for producing electricity.
- wind turbine blades are typically expected to last for 20 years, this is often not the case due to the damage caused by erosion of the leading edge necessitating blade repair.
- considerable resources are expended on continued maintenance operations to ensure optimum turbine performance.
- repair of the leading edge is not easy since it is typically carried out with the blade still mounted on the turbine. This also has significant cost and safety implications, particularly if the wind turbine is located offshore. Leading edge erosion may therefore result in reduced annual energy production and increased need for maintenance and repairs.
- most wind turbine blades have a joint bonded during manufacturing at the leading edge which is the most aerodynamically sensitive area, especially the outer third of the wind turbine blade.
- Such a joint introduces both shape irregularities, which degrade performance, and material boundaries which reduce erosion resistance.
- a leading-edge component such as an erosion shield
- leading-edge component typically requires manual placement by skilled workers as slight mounting misalignments risk causing reduced annual energy production and shorter life spans.
- length of the leading-edge protection components which become increasingly unwieldy.
- an object of the present disclosure to provide a method of assembling a wind turbine blade comprising a structural blade body and an aerodynamic component with increased precision.
- Another object of the present disclosure is to provide a aerodynamic component for a wind turbine blade that is easier to mount precisely.
- a first aspect of this disclosure relates to a method of attaching an aerodynamic component to a wind turbine blade body for manufacturing a wind turbine blade, the method comprising the steps of: providing an aerodynamic component comprising a first edge; providing a first spacer element, such as a first bond line, either at or adjacent to the first edge of the aerodynamic component, or on a first side of the wind turbine blade body, wherein the first bond line may optionally be provided as a first double-sided adhesive tape comprising a first adhesive layer at a first side of the first double-sided adhesive tape and a second adhesive layer at an second, opposite, side of the first double-sided adhesive tape and the first adhesive layer of the first double-sided adhesive tape may be attached either at or adjacent to the first edge of the aerodynamic component, or on the first side of the wind turbine blade body; arranging the aerodynamic component at a portion of the wind turbine blade body, such as a recess, a leading portion or a trailing portion of the wind turbine blade body;
- the aerodynamic component into a mounting position so that a step size between an exterior side of the aerodynamic component and an exterior surface of the wind turbine blade body at the first edge of the aerodynamic component is reduced or minimised; attaching, preferably via the first bond line, for example via the second adhesive layer, the aerodynamic component to the wind turbine blade body so that the first edge of the aerodynamic component is temporarily or detachably attached to the wind turbine blade body in the mounting position and so that a first compartment is formed between the aerodynamic component and the wind turbine blade body; injecting a first adhesive into the first compartment between the aerodynamic component and the wind turbine blade body preferably through one or more injection ports of the aerodynamic component, the one or more injection ports may extend from the exterior, e.g.
- the first spacer element acts as an adhesive barrier so as to prevent the first adhesive from exiting the first compartment between the first edge of the aerodynamic component and the wind turbine blade body; and allowing or causing the first adhesive to cure so as to fix the aerodynamic component to the wind turbine blade body in the mounting position and so that the aerodynamic component optionally forms at least part of the exterior surface, such as the leading edge or trailing edge of the wind turbine blade.
- the method of attaching an aerodynamic component to a wind turbine blade body may allow for better alignment, measurement, verification, and correction of the position of the components before they are permanently bonded together.
- This advantage stems from the use of a temporary fixing step via the first spacer element during the assembly process.
- the method enables precise alignment of the aerodynamic component to the wind turbine blade body. Initially, the first spacer element is attached either at or adjacent to the first edge of the aerodynamic component or on a first side of the wind turbine blade body. This initial attachment allows for the arrangement of the aerodynamic component at the portion of the wind turbine blade body.
- the first edge of the aerodynamic component is adjusted into a mounting position, minimizing the step size between the aerodynamic component and the blade body.
- This adjustment process ensures precise alignment and positioning of the components.
- the bond line is used to temporarily attach the aerodynamic component to the wind turbine blade body. Since the temporary or detachable fixing via the first bond line allows the operators to continually engage and disengage the aerodynamic component, the alignment of the aerodynamic component can be adjusted until assembly tolerances are met. Thus, this allows for further adjustments, measurements, and verifications to be made before the components are permanently bonded.
- first compartment between the aerodynamic component and the blade body created by the spacer element, facilitates the injection of a first adhesive through one or more injection ports of the aerodynamic component.
- the spacer element acts as an adhesive barrier, preventing the adhesive from exiting the compartment. This containment of the adhesive ensures controlled and precise application, minimizing the risk of unwanted adhesive spreading.
- the one or more injection ports may extend through the first spacer element to the first compartment. In other embodiments, the one or more injection ports may be distanced from the first spacer element.
- the first adhesive is injected, it is allowed or caused to cure, fixing the aerodynamic component to the wind turbine blade body in the desired mounting position. This curing process ensures a secure and durable bond between the components, resulting in a wind turbine blade with a properly positioned and aligned aerodynamic component.
- the alignment, measurement, verification, and correction of components are carried out before the adhesive is cured.
- This approach enables any necessary adjustments or corrections to be made, ensuring that the aerodynamic component is accurately positioned. Consequently, the method reduces the likelihood of mounting misalignments that could result in reduced annual energy production and shorter lifespan of the resulting wind turbine blade.
- the technical advantage provided by this method is the improved alignment and positioning accuracy in wind turbine blade manufacturing. It allows for precise adjustments and measurements, ensuring optimal component positioning before permanent bonding takes place. This advantage contributes to enhanced overall wind turbine performance, reduced maintenance requirements, and improved operational efficiency.
- the exterior side of the aerodynamic component may form part of the exterior aerodynamic surface of the wind turbine blade once the aerodynamic component is mounted onto the body.
- the exterior side of the aerodynamic component may form the leading edge or the trailing edge of the wind turbine blade.
- the aerodynamic component may be a structural component, e.g. the aerodynamic component may provide load bearing capability to the wind turbine blade.
- the aerodynamic component may be a fairing component and may thus define part of the exterior surface without providing load bearing capability to the wind turbine blade.
- the aerodynamic component is a leading edge fairing.
- the method may further comprise the steps of:
- a second spacer element such as a second bond line, either at or adjacent to a second edge of the aerodynamic component, or on a second side of the wind turbine blade body, wherein the second edge of the aerodynamic component is opposite of the first edge
- the second bond line may be provided as second double-sided adhesive tape comprising a first adhesive layer at a first side of the second double-sided adhesive tape and a second adhesive layer at an second, opposite, side of the second double-sided adhesive tape and the first adhesive layer of the second double-sided adhesive tape may be attached either at or adjacent to the second edge of the aerodynamic component, or on the second side of the wind turbine blade body;
- the aerodynamic component preferably via the second bond line, for example the second adhesive layer of the second double-sided adhesive tape, the aerodynamic component to the wind turbine blade body so that the second edge of the aerodynamic component is temporarily or detachably attached to wind turbine blade body in the mounting position and so that a second compartment is formed between the aerodynamic component and the wind turbine blade body.
- the second bond line for example the second adhesive layer of the second double-sided adhesive tape
- the second edge of the aerodynamic component is adjusted into a mounting position, minimizing the step size between the aerodynamic component and the blade body. This adjustment process guarantees that both edges of the aerodynamic component are properly aligned and positioned relative to the wind turbine blade body.
- the second bond line is used to temporarily or detachably attach the aerodynamic component to the wind turbine blade body. This temporary or detachable fixing via the second bond line provides increased stability during the assembly process, preventing undesired movements or misalignments of the aerodynamic component, which could negatively impact energy production and blade lifespan.
- the attachment via the second bond line ensures that the second edge of the aerodynamic component is securely fixed to the wind turbine blade body in the mounting position. This attachment creates a second compartment between the aerodynamic component and the blade body, similar to the previously mentioned first compartment.
- first and/or second adhesive(s) may be structural adhesive. This contrasts to the adhesive of the first and/or second bond line which generally comprise(s) or consist(s) of pressure-sensitive adhesives. Furthermore, the first and/or second adhesive(s) may be a low viscosity adhesive and may thus be injectable. Additionally or alternatively, the first side, and optionally the second side, of the wind turbine blade body may be a first side surface and a second side surface, respectively.
- first and/or second bond line may be provided as double-sided adhesive tape(s).
- first and/or second bond line may alternatively each be provided as a single adhesive layer provided in a line.
- a double-sided adhesive tape may be understood as an elongated backing layer having a first adhesive layer on one side and a second adhesive layer on the opposite side.
- the exterior side of the first adhesive layer is covered by a first peel layer and the exterior side of the second adhesive layer is covered by a second peel layer.
- the first and/or second adhesive layer may comprise a pressure sensitive adhesive that may be adapted to form a detachable bond.
- a temporary or a detachable attachment of the first and/or second edge of the aerodynamic component may be understood as the attachment being sufficient for maintaining the aerodynamic component in position during manufacturing but would be insufficient to maintain the aerodynamic component in position during operation of the wind turbine blade.
- a fixation of the aerodynamic component may be understood as a fixing which is sufficient to maintain the aerodynamic component in position during operation, for a large portion of or even for the entirety of the lifetime of the aerodynamic component.
- the fixing may in some embodiments be reversible, for example using thermoplastic adhesives, to allow the aerodynamic component to be replaced.
- the second compartment may be separate from the first compartment and wherein the method may further comprise:
- first barrier element and a second barrier element between the aerodynamic component and the wind turbine blade body so that the first compartment is bounded or delimited by the first bond line and the first barrier element and the second compartment is bounded or delimited by the second bond line and the second barrier element, wherein the first bond line and the first barrier element act as adhesive barriers so that during injection of the first adhesive, the first adhesive is prevented from exiting the first compartment;
- the one or more injection ports may extend from the exterior, e.g. the exterior side, of the aerodynamic component to the second compartment, wherein the second spacer element may act as an adhesive barrier so as to prevent the second adhesive from exiting the second compartment between the second edge of the aerodynamic component and the wind turbine blade body.
- the step of allowing or causing the first adhesive to cure may further comprise allowing or causing the second adhesive to cure.
- the second compartment is separate from the first compartment and thus has clear boundaries between them.
- the method incorporates a first barrier element and a second barrier element between the aerodynamic component and the wind turbine blade body. These barriers are arranged in conjunction with and adjacent to the first and second bond lines, respectively. The presence of the first and second barrier elements enhance the containment of the first and second adhesives within their respective compartments.
- the first compartment is bounded by the first bond line and the first barrier element, while the second compartment is bounded by the second bond line and the second barrier element.
- These barriers ensure that the injected adhesives are confined within their designated compartments, reducing or preventing any unwanted mixing or leaking.
- the one or more injection ports may extend through the second bond line to the second compartment. In other embodiments, the one or more injection ports may be distanced from the second bond line.
- the method ensures a controlled and contained application of adhesives, minimizing the risk of adhesive leakage or unwanted contact between the adhesives in the compartments.
- This containment provides a reliable and consistent bonding process, contributing to the overall stability and durability of the aerodynamic component attachment.
- first and/or second barrier elements may an open cell foam band and/or may include an adhesive, e.g. pressure-sensitive, on one side.
- the barrier elements may be adapted to adhere to either the aerodynamic component or the wind turbine blade body.
- the injection of the first adhesive and the second adhesive may be performed simultaneously or it may be performed separately, e.g. sequentially.
- the curing of the first and second adhesives may be performed separately but is preferably performed simultaneously. Since such a unified curing process may ensure that both adhesives solidify simultaneously, promoting uniformity and integrity in the bonding between the aerodynamic component and the wind turbine blade body. The synchronized curing process may enhance the overall structural strength and long-term performance of the wind turbine blade.
- first and second barrier elements may define a cavity there in between, which, during injection of the first and second adhesive is not filled with adhesive. Such an air-filled cavity may save weight without substantially compromising the attachment of the aerodynamic component.
- first adhesive may preferably fill the entirety of the first compartment and/or wherein the second adhesive may preferably fill the entirety of the second compartment.
- first compartment and the second compartment may together form a single, continuous compartment extending from the first spacer element to the second spacer element, for example from the first bond line to the second bond line.
- the method may streamline the assembly of the aerodynamic component. This integration eliminates the need to separately handle and manage two distinct compartments, which may reduce complexity and potential errors during the assembly process. If the profile of the aerodynamic component is shaped to match the shape of the portion of the body, the gap formed there in between can be minimized and thus, the additional weight of the cured first adhesive filling the first compartment can be reduced.
- first and/or the second bond line may comprise a first peel layer covering an exterior side of a first adhesive layer of the bond line.
- the method may further comprise a step of removing the first peel layer from the bond line preferably prior to positioning the respective bond line on either the aerodynamic component or wind turbine blade body.
- first and/or the second bond line(s) may comprise a second peel layer covering an exterior side of a second adhesive layer of the bond line.
- the step of providing the first and/or second bond line(s) on either aerodynamic component or wind turbine blade body may include maintaining the second peel layer on the exterior side of the second adhesive layer.
- the method may further comprise a step of removing the second peel layer of the first and/or second bond line(s) preferably prior to the step of attaching the aerodynamic component to the wind turbine blade in the mounting position.
- bond line on the aerodynamic component offers an advantage of reducing cycle time through parallel processing. By separating the tasks of blade preparation and bond line attachment, operators can simultaneously work on different stages of the manufacturing process, which may effectively optimise resource utilization and minimises idle time. This streamlined workflow may not only enhance overall efficiency and productivity but may also allow manufacturers to produce more wind turbine blades within a given timeframe, meeting the growing demand for renewable energy.
- the aerodynamic component may comprise one or more drain holes.
- air within the first and/or second compartment may be vented through the one or more drain holes.
- the inclusion of one or more drain holes in the aerodynamic component may provide a significant advantage by allowing for the venting of air trapped within the compartments during adhesive injection, potentially reducing voids in the adhesives and thus improving bonding quality.
- the structural integrity of the blade is enhanced, which may reduce the risk of delamination and improving long-term performance.
- the efficient removal of air pockets may decrease the likelihood of stress concentration, crack propagation, and moisture ingress, and may thus lead to reduced maintenance requirements and optimized operational lifespan.
- first and/or second barrier elements may be adhesive barrier element(s) and/or may be air permeable so that, during injection of the first and/or second adhesive, air within the first and/or second compartment is vented through the respective barrier element before exiting through the one or more drain holes.
- first and/or second barrier element(s) may be air impermeable.
- barrier elements as air permeable, air can escape from the first and second compartments through the barrier elements e.g. to be vented via the drain holes. Accordingly, the risk of void formation in the cured adhesives is reduced.
- the aerodynamic component may be supported via a plurality of straps during the step(s) of adjusting the aerodynamic component into the mounting position and/or the step(s) of attaching, via the second adhesive layer, the aerodynamic component to the wind turbine blade body.
- the straps may in principle be any kind of support, but is advantageously a suspended support.
- the wind turbine blade body may be provided with the portion facing downwards preferably prior to the step of arranging the aerodynamic component at the portion of the wind turbine blade body.
- the step(s) of removing the second peel layer may comprise spacing the plurality of straps from the wind turbine blade body, preferably by inserting one or more inserts between the plurality of straps and the wind turbine blade body. By spacing the plurality of straps, it may be easier to access and remove the second peel layer and may reduce the risk of severing the peel layer during removal.
- the portion of the wind turbine blade body is a recess.
- the first side, and optionally the second side, of the wind turbine blade body may form part of the recess, such as the floor of the recess.
- the first side may be delimited by the first spacer element and optionally the first barrier element
- the second side may be delimited by the second spacer element and optionally the second barrier element.
- the first side, and preferably the second side, of the wind turbine blade body may be parallel to adjacent portions of the exterior surface of the wind turbine blade body, respectively.
- the first side and preferably the second side may follow the profile of the exterior surface of the wind turbine blade body.
- the aerodynamic component comprises at least one of a leading edge erosion protection layer, one or more vortex generators, a plurality of serrations, one or more T- spoilers.
- a second aspect of this disclosure relates to a kit of parts for the attachment of an aerodynamic component to a wind turbine blade body of a wind turbine blade, the kit of parts comprising: the aerodynamic component including: o a curved profile having an interior side, an exterior side, a first edge and a second edge, wherein the exterior side of the curved profile is for defining a leading edge or a trailing edge of the wind turbine blade and is preferably substantially U-shaped; o one or more injection ports extending through the curved profile from the exterior side to the interior side, and o preferably one or more drain holes extending through the curved profile from the exterior side to the interior side;
- first spacer element such as a first bond line, e.g. a first double-sided adhesive tape, configured for being attached to the interior side of the aerodynamic component at or adjacent to the first edge of the aerodynamic component
- second spacer element such as a second bond line, e.g. a double-sided adhesive tape, configured for being attached to the interior side of the aerodynamic component at or adjacent to the second edge of the aerodynamic component
- kit of parts may further comprise: a first barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the first bond line so as to define a boundary of a first area of the interior side of the aerodynamic component, wherein the first area forms part of a first compartment when the aerodynamic component is attached to the wind turbine blade body; and/or a second barrier element configured for being attached on the interior side of the aerodynamic component adjacent to the second bond line so as to define a boundary of a second area of the interior side of the aerodynamic component, wherein the second area forms part of a second compartment when the aerodynamic component is attached to the wind turbine blade body.
- a third aspect of this disclosure relates to a wind turbine blade, comprising: a body including a portion, e.g.
- the body and the aerodynamic component may extend along a longitudinal course from a root to a tip.
- the body and the aerodynamic component may comprise a root region (30) and an airfoil region with the tip.
- the body and the aerodynamic component may comprise a chord line extending between a leading edge of the aerodynamic component and a trailing edge of the body.
- the body and the aerodynamic component may comprise an aerodynamic exterior blade surface which includes the pressure side and the suction side. The pressure and suction sides may be partly formed by the body and partly by the aerodynamic component.
- the wind turbine blade may further comprise: a first barrier element arranged between the aerodynamic component and the first side of the body, wherein the cured first adhesive at least partly, preferably entirely, fills a first compartment extending from the first spacer element to the first barrier element between the aerodynamic component and the first side of the body; preferably a second barrier element arranged between the aerodynamic component and the first side of the body, wherein a cured second adhesive at least partly, preferably entirely, fills a second compartment extending from the second spacer element to the second barrier element between the aerodynamic component and the second side of the body; and preferably a cavity extending from the first barrier element to the second barrier element and between the portion of the body and the aerodynamic component.
- the barrier element(s) may provide the advantage of preventing filling the entire compartment between the body and aerodynamic component and between the spacer elements with adhesive and may thus reduce the weight of the wind turbine blade.
- the cavity may be air-filled.
- the aerodynamic component may comprise one or more drain holes extending through the aerodynamic component preferably to the cavity.
- the drain holes are adapted to allow drainage of condensation within the aerodynamic component, e.g. the cavity.
- first and/or second barrier element may be air permeable preferably so as to allow air from the first and/or second compartment to vent through the first and/or second barrier element, respectively, during infusion of the first and/or second adhesive, respectively.
- a fourth aspect of this disclosure relates to a wind turbine blade, preferably according to the third aspect, which is obtainable by a method according to the first aspect.
- Fig. 1 is a schematic perspective view of a wind turbine.
- Fig. 2 is a schematic perspective view of a wind turbine blade for a wind turbine as shown in Fig. 1.
- Fig. 4 is a schematic cross-sectional view of a double-sided adhesive tape for use in assembling the aerodynamic component and the wind turbine blade body of Fig. 3.
- Fig. 5 is a schematic perspective view of a longitudinal section of the aerodynamic component and the wind turbine blade body during assembly thereof.
- the longitudinal section has been cut out from the remainder of the aerodynamic component and the wind turbine blade body.
- Fig. 6 is a schematic cross-sectional view similar to Fig. 4 showing the aerodynamic component attached to the wind turbine blade body.
- Fig. 1 illustrates a conventional modern upwind wind turbine 2 according to the so-called "Danish concept" with a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft which may include a tilt angle of a few degrees.
- the rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a blade root 16 nearest the hub and a blade tip 14 furthest from the hub 8.
- Fig. 2 shows a schematic view of an exemplary wind turbine blade 10.
- the wind turbine blade 10 has the shape of a conventional wind turbine blade with a root end 17 and a tip end 15 and comprises an exterior surface 27 defining a root region 30 closest to the hub, a profiled or an airfoil region 34 furthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34.
- the blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10, when the blade is mounted on the hub 8, and a trailing edge 20 facing the opposite direction of the leading edge 18.
- the blade 10 comprises a body 13 and an aerodynamic component 40 attached to an outer third of the wind turbine blade in the tip region 34 but may have a shorter or greater longitudinal extent, for example the aerodynamic component may extend in the entire airfoil region 34 as well or even along the entire length of the wind turbine blade 10.
- the leading edge 18 is partly defined by the body 13, i.e. in the innermost two thirds of the blade length, and partly by the aerodynamic component 40, i.e. in the outermost third of the blade length.
- the aerodynamic component 40 may define part of the trailing edge.
- the airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub.
- the diameter (or the chord) of the root region 30 may be constant along the entire root region 30.
- the transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34.
- the chord length of the transition region 32 typically increases with increasing distance r from the hub.
- the airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10.
- the width of the chord decreases with increasing distance r from the hub.
- a shoulder 38 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 38 is typically provided at the boundary between the
- chords of different sections of the blade normally do not lie In a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.
- the aerodynamic component 40 has a curved profile 41, which is generally U- shaped, which terminates at a first edge 42 and at a second edge 42' opposite of the first edge 42.
- the aerodynamic component defines an interior side 44, which is intended to face the body 13, and an exterior side 45, which is intended to define part of the exterior surface 27 of the blade 10.
- the aerodynamic component 40 has been prepared by attaching a first spacer element 60 implemented here as a first bond line in the form of a first double-sided adhesive tape 60, to the interior side 44 adjacent to the first edge 42 and by attaching a second spacer element 60' implemented here as a second bond line in the form of a second double-sided adhesive tape 60', to the interior side 44 adjacent to the second edge 42'. Furthermore, a first barrier element 66 has been attached to the interior side 44 adjacent to but distanced from the first double-sided adhesive tape 60 thus defining a first area 48 there in between. Likewise, a second barrier element 66' has been attached to the interior side 44 adjacent to but distanced from the second double-sided adhesive tape 60' thus defining a second area 48' there in between.
- the barrier elements 66, 66' are an open cell foam band including an adhesive, e.g. pressure-sensitive, on one side.
- the aerodynamic component 40 is provided with injection ports 46, 46' extending from the exterior side 45 to the interior side 44 both within the first area 48 and the second area 48'.
- the body 13 of the wind turbine blade 10 (which is best seen in Fig. 2) provides the structural strength of the wind turbine blade 10.
- the body 13 comprises a portion 19 with a first side 21 on the pressure side 22 and a second side 23 on the suction side 24.
- the body 13 can further comprise a vent hole 28 for venting e.g. condensation within the body 13 as shown.
- the portion 19 is a leading portion but may in other embodiments for example be a trailing portion.
- the leading portion 19 is intended to be covered by the aerodynamic component 40.
- the body 13 also defines part of the exterior surface 27 of the wind turbine blade.
- the double-sided adhesive tapes 60, 60' and/or the barrier elements 66, 66' could alternatively be placed on the first and second sides 21, 23 of the body 13, respectively.
- the first and second double-sided adhesive tape 60, 60' is shown in greater detail in Fig. 4.
- Each double-sided adhesive tape 60, 60' comprises a layered structure with a backing layer 61, 61' forming the middle layer and sandwiched between a first adhesive layer 62, 62' and a second adhesive layer 64, 64'.
- a first peel layer 63, 63' covers the exterior side of the first adhesive layer 62, 62' and a second peel layer 65, 65' covers the exterior side of the second adhesive layer 64, 64'.
- the first peel layer 63, 63' is removed prior to attaching to the aerodynamic component 40 to arrive at the arrangement as shown in Fig. 3.
- Fig. 5 shows a single longitudinal section of the aerodynamic component 40 and the body 13 but it will be appreciated that the same approach applies to the remainder of the aerodynamic component 40.
- Fig. 5 illustrates that an insert 69 is inserted between the strap 68 and the suction side 24 of the body 13 (a similar insert is also inserted between the strap 68 and the pressure side 22 of the body 13 but this is not shown in Fig. 5).
- such inserts 69 can be omitted to allow operators to align the aerodynamic component 40 on the body 13.
- the operators proceed to adjust and align the first edge 42 of the aerodynamic component 40 into a mounting position as shown in Figs. 5-6 so that a step size 43 (best seen in Fig. 6) between an exterior side 45 of the aerodynamic component 40 and an exterior surface 27 of the wind turbine blade body 13 (i.e. on the pressure side 22) at the first edge 42 of the aerodynamic component 40 is reduced or minimised.
- the second edge 42' of the aerodynamic component 40 is adjusted and aligned into the mounting position as shown in Figs. 5-6 so that a step size 43' (best seen in Fig.
- the double-sided adhesive tapes 60, 60' temporarily attach the aerodynamic component 40 to the body 13 and a first and a second compartment 50, 50' is defined between the interior side 44 of the aerodynamic component 40 and the first and second side 21, 23 of the body 13, respectively.
- the first compartment 50 is bounded by the first double-sided adhesive tape 60 and the first barrier element 66.
- the second compartment 50' is bounded by the first double-sided adhesive tape 60' and the second barrier element 66.
- the aerodynamic component 40 can be easily detached from the body 13 by pulling the first and/or second edges 42, 42', and adjusted until the position is satisfactory. The aerodynamic component 40 is then easily reattached by pushing exterior side 45 so that the double-sided adhesive tapes 60, 60' adhere again to the body 13.
- a first adhesive 52 is injected through injection ports 46 (best seen in Figs. 3 and 6) to fill the first compartment 50 and a second adhesive 52' is injected through injection ports 46' (best seen in Figs. 3 and 5-6) to fill the second compartment 50'.
- the first and second adhesives 52, 52' are relatively low viscosity structural adhesives, for example epoxy, vinyl ester, methyl methacrylate (MMA), or polyester.
- the double-sided adhesive tapes 60, 60' and barrier elements 66, 66' prevent the first and second adhesives 52, 52' from exiting their respective compartments 50, 50'.
- the barrier elements 66, 66' are air permeable while the double-sided adhesive tapes 60, 60' are generally air impermeable.
- the aerodynamic component 40 is provided with drain holes 47 which extend from the exterior side 45 to the cavity 51 and which allow the build-up of air in the cavity 51 to vent through these drain holes 47.
- the drain holes 47 also function as a drainage for condensation build up in the cavity 51 during operation of the blade 10.
- the adhesives 52, 52' cure and exhibit a very low void and defect fraction due to the air permeability of the barrier elements 66, 66'.
- the aerodynamic component 40 is fixed to the body 13 so that the aerodynamic component 40 forms at least part of the leading edge 18 of the wind turbine blade 10 as best seen in Fig. 2.
- any gap between the first and second edges 42, 42' is filled with sealant 67, 67' to ensure a smooth transition of the exterior surface 27 between the body 13 and the aerodynamic component 40.
- the barrier elements 66, 66' are omitted and thus the first and second compartments 50, 50' form a single, continuous compartment.
- the interior side 44 and the leading portion 19 are advantageously shaped to substantially match each other since the entirety of the space there in between is filled with the adhesives 52, 52'.
- Fig. 7 a different embodiment is shown.
- the portion of the body 13 comprises a recess formed in the exterior surface 27 of the wind turbine blade.
- the first side 21 and the second side 23 form part of the floor of the recess.
- the first and second side 21, 23 define respective surfaces which are parallel (but offset inwardly) to parts of the final exterior surface of the wind turbine blade.
- the aerodynamic component 40 is, in this embodiment, shown as a flat piece and may, for example, comprise one or more vortex generators or one or more T-spoilers.
- the aerodynamic component 40 could also be a flat part of the leading-edge protection component having parallel exterior surface. Also, the recess may continue further from the aerodynamic component 40 to accommodate one or more further components.
- the transition from the second side 23 of the recess to the exterior surface 27 at the sealant 67' may be further distanced from the aerodynamic component 40 to accommodate these further components.
- the first edge 42 and the second edge 42' of the aerodynamic component are detachably attached to the first spacer element 60 and second spacer element 60', respectively so as to form a single continuous compartment 50 delimited by the floor of the recess, the spacer elements 60, 60' and an interior side of the aerodynamic component 40.
- the first side 21 and the second side 23 are arranged in parallel to adjacent portions of the exterior surface 27, respectively. This allows an operator to easier align the aerodynamic component 40 in a flush arrangement with the exterior surface 27 to reduce or minimise detrimental aerodynamic effects.
- an adhesive 52 can be injected, e.g. via one or more injection holes (not shown) of the aerodynamic component 50. Air within the compartment 50 prior to adhesive injection can be vented e.g. a vent hole (not shown).
- the transition between the exterior surface 27 and the first edge 42 and second edge 42' is filled with a sealant 67, 67' (or filler material) to ensure a smooth transition of the exterior surface 27 between the body 13 and the aerodynamic component 40.
- the sealant 67, 67' may have a lower elastic modulus than the adhesive 52, 52'.
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Abstract
L'invention concerne un procédé de fixation d'un composant aérodynamique à un corps de pale d'éolienne pendant le processus de fabrication. Tout d'abord, un élément d'espacement est fixé soit au composant aérodynamique soit au corps de pale d'éolienne. Le composant aérodynamique est ensuite disposé au niveau de la partie du corps de pale, et le premier bord du composant aérodynamique est ajusté dans une position de montage pour réduire au minimum la taille de pas entre le composant aérodynamique et le corps de pale. Le composant aérodynamique est temporairement fixé à l'aide de l'élément d'espacement, ce qui crée un compartiment entre le composant aérodynamique et le corps de pale. Un premier adhésif est injecté dans ce compartiment par l'intermédiaire d'orifices d'injection dans le composant aérodynamique, l'élément d'espacement servant de barrière pour empêcher l'adhésif de fuir. Enfin, l'adhésif peut durcir, ce qui fixe de manière permanente le composant aérodynamique en place.
Applications Claiming Priority (2)
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EP23192243 | 2023-08-18 | ||
EP23192243.6 | 2023-08-18 |
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WO2025040587A1 true WO2025040587A1 (fr) | 2025-02-27 |
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PCT/EP2024/073105 WO2025040587A1 (fr) | 2023-08-18 | 2024-08-16 | Pale d'éolienne dotée d'un composant aérodynamique |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
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US20120024457A1 (en) * | 2011-05-24 | 2012-02-02 | General Electric Company | Method and System for Bonding Wind Turbine Blades |
US20180266388A1 (en) * | 2017-03-15 | 2018-09-20 | General Electric Company | Blade Sleeve for a Wind Turbine Rotor Blade and Attachment Methods Thereof |
US20190360457A1 (en) * | 2016-09-15 | 2019-11-28 | Vestas Wind Systems A/S | Method of attaching a tip extension to a wind turbine blade |
WO2022214428A1 (fr) * | 2021-04-09 | 2022-10-13 | Lm Wind Power A/S | Pale d'éolienne dotée d'un carénage |
WO2022262921A1 (fr) * | 2021-06-18 | 2022-12-22 | Vestas Wind Systems A/S | Bouclier de protection de bord d'attaque |
-
2024
- 2024-08-16 WO PCT/EP2024/073105 patent/WO2025040587A1/fr unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
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US20120024457A1 (en) * | 2011-05-24 | 2012-02-02 | General Electric Company | Method and System for Bonding Wind Turbine Blades |
US20190360457A1 (en) * | 2016-09-15 | 2019-11-28 | Vestas Wind Systems A/S | Method of attaching a tip extension to a wind turbine blade |
US20180266388A1 (en) * | 2017-03-15 | 2018-09-20 | General Electric Company | Blade Sleeve for a Wind Turbine Rotor Blade and Attachment Methods Thereof |
WO2022214428A1 (fr) * | 2021-04-09 | 2022-10-13 | Lm Wind Power A/S | Pale d'éolienne dotée d'un carénage |
WO2022262921A1 (fr) * | 2021-06-18 | 2022-12-22 | Vestas Wind Systems A/S | Bouclier de protection de bord d'attaque |
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